Asian Food Science Journal

13(3): 1-11, 2019; Article no.AFSJ.51947

ISSN: 2581-7752

HACCP Plan and Adoption of HACCP Metasystem in

the Tea Industries of Bangladesh
I. Ahmad1*, R. S. Chowdhury1, Rayhan Uddin1, A. Shakawat1, W. U. Rahman1
and Wahidu Zzaman1
1
Department of Food Engineering and Tea Technology, Shahjalal University of Science and
Technology, Sylhet-3114, Bangladesh.

Authors’ contributions

The work was carried out in collaboration among all authors. All authors read and approved the final
manuscript.

Article Information

DOI: 10.9734/AFSJ/2019/v13i330106
Editor(s):
(1) Dr. Aneta Popova, Chief Assistant Professor, Department of Catering and Tourism, University of Food Technologies,
Bulgaria.
Reviewers:
(1) Mariana-Atena Poiana, Banat’s University of Agricultural Sciences and Veterinary Medicine “King Michael I of Romania”,
Romania.
(2) Tarek Ahmed El-Desouky, National Research Centre, Egypt.
(3) Kaushal Kishore Choudhary, Jai Prakash University, India.
Complete Peer review History: http://www.sdiarticle4.com/review-history/51947

Received 07 August 2019

Original Research Article Accepted 11 October 2019
Published 04 December 2019

ABSTRACT

HACCP (Hazard Analysis and Critical Control Points) metasystem is a concept not much familiar to
the tea industries of Bangladesh. This study was conducted to investigate the issue of food safety
through HACCP metasystem and conduct a hazard analysis to make a comprehensive model of
HACCP plan for the tea industries of Bangladesh. Both qualitative and quantitative data analysis
was used to determine the CCPs (Critical Control Points) or OPRPs (Operational Pre-Requisite
Programs) and design a HACCP plan through risk assessment and seven logical approaches. Two
OPRPs and CCPs were determined. The derived CCPs were the biological hazard in the
cultivation stage and the physical hazard in the processing step namely CTC (Crush, Tear and
Curl) and Googy shifter step. The biological hazard in the cultivation stage can be controlled by
proper application of GAP (Good Agricultural Practice) while the physical hazard can be controlled
in the processing step by proper maintenance of the magnetic arrestor. Considering the benefits
and constraints, standard processing procedures and guarantees of food safety of tea as well as to
stay in the competitive global market the tea industries should adopt HACCP metasystem.
_____________________________________________________________________________________________________

*Corresponding author: Email: iftekharfet.sust@yahoo.com;


Keywords: Tea industry; food safety; HACCP metasystem; CCPs; OPRPs.
1. INTRODUCTION
Tea is one of the most popularly consumed and
the cheapest beverages in the world and ranks
following to water [1]. This safe, mildly
stimulating and delicately flavored brew is
prepared from the young, tender leaves of a
heterogeneous self-incompatible and cross-
pollinated evergreen shrub Camellia sinensis
[2,3].
For the time being, tea has been spread all over
the world and become a leading cash crop in
modern world agriculture with boosting
production and of cultivating area [4] and today,
Bangladesh has 166 commercial tea estates,
including many of the world's largest plantations
[5].
Few years back, Bangladesh was a leading tea
producing and exporting country. But currently, it
is stumbling in the global market to compete
because of the poor quality of black tea.
Significant growth of internal demand, lack of
high yield varieties, backdated knowledge, poor
technology, and uncertain hazardous processing
units, etc. are the major findings concerning the
loss of the potential tea industries of Bangladesh
[6,7].
During the past two decades, public awareness
and concern regarding food safety have
increased both in developed and developing
countries and as a result, the governments as
well as respective food processing industries, are
currently intensifying their efforts to improve the
levels of food safety [8-11].
With respect to hazard and safety concern,
HACCP is a systematic approach to food safety
which identifies, evaluates and controls
significant hazards throughout the whole chain of
food production [12-16]. It is recognized essential
for Food Safety Management System (FSMS)
and necessary to concretize the GMP (Good
Manufacturing Practices) and PRP (Pre-requisite
Programs) measures on one hand and to look for
additional hazards assessment and
implementation of control measures through a
company specific on the other hand [17-20].
Metasystem technique which defined as the
process to assure quality on an ongoing process
with periodic verification and certification by an
unbiased third party has been increasingly
2
Ahmad et al.; AFSJ, 13(3): 1-11, 2019; Article no.AFSJ.51947
adopted to assess the overall effectiveness of
HACCP based FSM systems addressing a broad
range of research questions with regard to food
safety, presence of microbial contamination in
foods, risk assessment of foodborne pathogens,
occurrence of foodborne diseases, and barriers
to implementation of FSM systems [21-25].
So to hold on the competitive international
market and to meet the increasing demand as
well as pressure created by various local (both
private & public) and international institutions to
ensure higher standard of food safety and quality
and nutritional safety of the consumers there is
no alternative to adopt and initialize a food safety
management metasystem of HACCP in tea
industries of Bangladesh [17,26].
As there having a less available information
about physical, chemical and biological safety
hazard analysis in all the processing steps from
cultivation to storage as well as lack of sufficient
research work on HACCP in tea Industries of
Bangladesh therefore, present research work
was intended to investigate the issue of food
safety through HACCP meta system and conduct
hazard analysis to make a comprehensive model
of HACCP plan for the tea industries of
Bangladesh.
2. MATERIALS AND METHODS
A systematic approach was carried out for
hazard identification, assessment, and adoption
of control measures for the tea industries of
Bangladesh in 2016. Six different tea industries
(Two governments and semi-government, two
private national, two private multinational) were
selected in this connection. These three types of
industries were selected to get the overall idea
about the status and the effectiveness of HACCP
based FSM systems in tea industries of
Bangladesh.
The approach required proper planning which
started with the formation of a HACCP team [27].
In this study the HACCP team was formed with a
number of HACCP experts and tea experts who
conducted a series of face to face interviews
based on a questionnaire reported by [28] with
some modification with the managerial of the
industries regarding quality assurance, which
helped to justify the scenarios of the present
condition of the industries to initialize HACCP
meatsystem.
 Ahmad et al.; AFSJ, 13(3): 1-11, 2019; Article no.AFSJ.51947

According to the approach hazard assessment,
strategy to control hazard by combining PRPs,
OPRPs and HACCP plan (By establishing CCPs)
was established to construct a comprehensive
HACCP metasystem model for tea industries of
Bangladesh. The overall activities under the
approach can be summarized as (Fig. 1).
2.1 Risk Assessment
The team assessed the risks of physical and
chemical hazards after visiting, inspecting and
interviewing with the managerial of different tea
industries whereas the risk of potential biological
hazards was assessed in both tea samples and
ambiance of different processing steps (from
cultivation to storage) by commencing necessary
laboratory works at a microbiology laboratory.
PDA (Potato Dextrose Agar) and SDA
(Sabouraud Dextrose Agar) were used for
microbial growth and the CFU (Colony Forming
Unit) was determined in the both media.
The risk identified was assessed by the severity
or the effect of the hazard in relation to the
probability in which the hazard can occur in the
end product if the considered specific control
measures are not present or are failing to take
into consideration the next steps in the process
where an elimination or reduction to an
acceptable level is possible and taking into
consideration the existing correct implemented
Pre-requisite Programs (PRPs). The risk was
assessed by an estimated method reported by
[29,30] with some modification by setting
different levels of severity/effect and different
levels of likelihood/probability, and by assigning
a value to each level. The likelihood was
evaluated based on the company’s experience
(historical background, customers’ and
consumers’ claims and non-conformities) by
establishing the following criteria (Table 1)
whereas the severity was evaluated in response
to human health according to (Table 2).
A hazard was considered significant if the
probability (P) value by the severity (S) value (P
×S) was over 8. The hazards that were non-
significant (P × S ≤ 8) did not move on to the
next step in this study, and these hazards could
be managed by the PRPs.
The Risks which were significant, the control
measures were classified according to whether
they could be managed through OPRPs or by
the HACCP plan (by establishing CCPs).
According to ISO 22000 the OPRPs contain the
food safety hazard, control measure, monitoring
procedures, corrective actions, responsibilities
and monitoring records while the HACCP
plan contains the identification of critical control
points (CCPs), control measures, determination
of critical limits for CCPs, monitoring procedures,

Table 1. Evaluation of probability (P) with their assigned value

Category Criteria Value

Very Next step in the production process may eliminate or reduce the hazard to an 1
Small acceptable level and limited and local contamination
Small Absence of the general measures and the chance of hazard occurrence in the 2
end product is very limited
Real Failing or lacking of the specific control measure and hazard occurrence in the 3
end product is in a certain percentage in the associated batch
High Failing or lacking of the specific control measure result in a systematical error 4
and high probability of hazard occurrence in all end products of the associated
batch

Table 2. Evaluation of severity (S) with their assigned value

Category Criteria Value

Limited The hazard can never reach a dangerous concentration 1
Moderate The hazard can provoke only minor health problems 2
Serious The hazard may provoke some health problems in immune- 3
compromised/allergic individuals, or may involve medical consultation and has
long term effect
Very The hazard may provoke significant problems, not only in immune- 4
Serious compromised/allergic individuals, but also in healthy people, which may
involve hospitalization or potential chronic disease

3
 Ahmad et al.; AFSJ, 13(3): 1-11, 2019; Article no.AFSJ.51947

Fig. 1. A framework for collection and analysis of data to construct the HACCP plan for tea
industries of Bangladesh
Table 3. Remarks of seven logical approaches according to [31]

Code Variables/Remarks
a Its effect on identified food safety hazards relative to the strictness applied;
b Its feasibility for monitoring (e.g. ability to be monitored in a timely manner to enable
immediate corrections);
c Its place within the system relative to other control measures
d The likelihood of failure in the functioning of a control measure or significant processing
variability
e The severity of the consequence(s) in the case of failure in its functioning
f Whether the control measure is specifically established and applied to eliminate or
significantly reduce the level of hazard(s);
g Synergistic effects (i.e. interaction that occurs between two or more measures resulting in
their combined effect being higher than the sum of their individual effects)

corrective actions, and responsibilities and
monitoring records. The selection and
categorization was carried out using the seven
logical approaches that includes assessments
concerning the following (Table 3).
Each control measure was scored for the seven
variables. If the final score was > 17, it would be
managed by the HACCP plan (by establishing
CCP) and if the final score was < 17, it would be
managed by OPRPs.
2.2 Statistical Analysis
Among the statistical tools of measures of
dispersion, mode was used to calculate the risk
assessment to identify the CCP’s for the next
phase of the full model of HACCP for the tea
industries of Bangladesh. In the case of two or
more mode values, the HACCP team preferred
the maximum rating to consider every possible
hazard.
3. RESULTS AND DISCUSSION
HACCP team had selected the factors according
to their ideas regarding the adoption of HACCP
metasystem. Then the mathematical percentage
of the factors had been expressed by the
HACCP team choosing in accordance with the
types of benefits and constraints. Among the
selected industries few industries follow their

4

routine work which partially compliance with
HACCP. Hence these were considered as partial
implementers of HACCP metasystem w while the
rests weren’t concern about similar types of
activities relating to HACCP metasystem and in
this regard, they were considered as non non-
commenced industries. The industries which had
partially implemented and others were not
implemented HACCP plan differedffered in different
circumference such as in benefits, costs, market
access, customer satisfaction and acceptance,
income, quality, and shelf life, etc. parameters.
According to the collected data, the benefits can
be presented as profit oriented was 55%,
technical efficiency oriented was 18% and
human resource oriented was 27% (Fig. 2).
Wijayasiri and Jayaratne [32] reported that the
benefits, better market access, gain of customer
acceptance, reduction in waste and
18%
55%
0%
Fig. 2. Percentage of benefits by adopting HACCP in different tea industries of Bangladesh
0%
31% 26%
43%
Fig. 3. Percentage of constraints faced by adopting HACCP in different tea industries of
Bangladesh
Ahmad et al.; AFSJ, 13(3): 1-11, 2019;; Article no.
no.AFSJ.51947
enhancement of efficiency increased with the
implementation of HACCP metasystem in tea
industries of Srilanka. Similar observation
towards the improvement of overall quality
performance, the efficacy of processing,
recording and personnel hygiene was reported
by Lokunarangodage, Wickramasinghe [33] in
Srilankan tea industry.
Besides
ides the benefits, the HACCP adopters faced
various constraints. Here the utilization of the
internal environment and monetary problems are
found as the prominent obstacles (Fig. 3).
Gajanayake, Jayasinghe-Mudalige
Mudalige [34] reported
in case of Srilankan Tea processing Industries
that training of employeess conforms to HACCP
plan and monetary issue and utilization of
internal environment to allocate physical
resources were the prime constraints faced by
the HACCP adopters.
Profit Oriented
27%
Technical Efficiency
Oriented
Human Resource
Oriented
Attitudes of employees in
the firm
Internal environment in
the firm
Monetary problem faced
by the firm
5

3.1 Microbial Hazards in Different Steps
of Tea Processing
The Graphs representing the Total Microbial load
in CFU at the ambiance of the different section of
tea from field to final Products (Fig. 4). It was
observed that cultivation steps i.e. Nursery and
Matured field possess on average 120 CFU and
115 CFU respectively hence the risk was
prominent in this step. From the graphical
representation (Fig. 4) it was observed that the
drying and storage steps contained a lower
amount in CFU. The reason might the presence
of heating source and High temperature at the
drying step. Whereas the outcomes were
completely unsatisfactory for good quality tea as
it exhibits the retention of the opportunity of the
final product being contaminated by Biological
hazards. The withering and rolling and
fermentation step contained microbial load about
76 CFU and 81 CFU. But it was evident that for
food safety purpose microorganism prevalence
implies to negative impact. According to Mishra,
Gautam [35] it was explored that during storage
under high humidity, absorption of moisture may
encourage fungal growth and result in quality
loss of the product. Hence, in drying and grading
as well as subsequent packaging and storage
their existence should be zero. The load would
be lower enough in every step of factory level, if
there had adequate construction facilities, strict
hygienic precautions, maintaining positive
hydrostatic pressure at all times and others
factors were correctly maintained according to
140
120
100
80
60
40
20
0
Nursery Matured Field Withering and Fermentation
Rolling
Fig. 4. Total microbial load in CFU at different steps of tea processing in different tea
industries
6
Ahmad et al.; AFSJ, 13(3): 1-11, 2019; Article no.AFSJ.51947
the safety issue. Considering the necessary
factors (Probability, Likelihood, occurrence and
correcting action in following steps, etc.) the risk
was determined by setting different values by the
HACCP team and analyzed by above-mentioned
strategy.
3.2 Risk Assessment and Control
Strategies
The possible hazards identified in each step of
the process along with their forms and P & S
ratings were shown in (Table 4). Concerning the
P×S value (Table 4), it was explored that at
cultivation stage, to control chemical and
biological hazard PRP and OPRP can be
adopted respectively. In the case of the
transportation stage to check chemical and
biological hazard OPRP/CCP should be
established. At the CTC and Googy shifter step,
the biological and physical hazards can be kept
in limit by establishing PRP and OPRP/CCP.
It was also clearly observed that at fermentation
stage Physical and chemical hazard can be
controlled by PRP while the biological hazard
can be controlled by establishing OPRP/CCP.
On the other hand in case of plucking of tea
shoots, loading on the withering trough, withering
and rolling, pre-conditioning (rolling / rotor vane),
drying, shifting, grading, and packing and
storage steps potential hazards can be
minimized by adopting PRP as the P×S score
was ≤ 8.
PDA SDA
Drying Storage
 Ahmad et al.; AFSJ, 13(3): 1-11, 2019; Article no.AFSJ.51947

Table 4. Risk assessment in different steps of tea processing (from cultivation to storage) with
respective ratings in different tea industries of Bangladesh

Steps Hazard Forms of Probability Severity P×S PRP

hazard rating rating Y/ N
Cultivation Pesticide residue Chemical 4 1 4 Y
heavy metals 2 2 4 Y
plant disease and insect Biological 4 3 12 N
infections
Plucking of tea Foreign objects Physical 3 2 6 Y
shoots human pathogens, snails Biological 2 1 2 Y
Transportation Damage of the plucked leaves Physical 3 3 9 N
from garden to by excessive pressing
factory Chemical fertilizer Chemical 1 3 3 Y
contamination by fuel of 3 2 6 Y
vehicles
human pathogens Biological 1 2 2 Y
Loading on Foreign bodies likes dust, Physical 2 2 4 Y
withering trough stone etc.
human pathogens Biological 2 1 2 Y
Withering Foreign bodies (dust) Physical 2 2 4 Y
Pre-conditioning Metallic contamination Physical 3 2 6 Y
(rolling / Microbial growth Biological 3 2 6 Y
rotorvane)
CTC & Googy Metallic contamination Physical 3 3 9 N
shifter Microbial growth Biological 2 3 6 Y
Fermentation Extraneous matter Physical 1 1 1 Y
contamination by washing Chemical 2 2 4 Y
chemicals
Microbial growth Biological 3 3 9 N
Drying Moisture Physical 2 3 6 Y
Sifting Metallic contamination Physical 2 2 4 Y
Grading Foreign matter Physical 2 2 4 Y
Packing Contamination by migration of Chemical 3 2 6 Y
packaging component
Storage Proliferation of microorganisms Biological 2 3 6 Y
Y = Yes; N = No

Table 5. Seven logical approaches to determine CCPs or OPRPs for tea industries of
Bangladesh

Steps Hazard Forms of Seven logical Total OPRP CCP

hazard approaches rating Y/N Y/N
a b c d e f g
Cultivation Disease and Biological 3 3 2 3 3 2 3 19 N Y
insect damage
Infections
Transportation Damage of the Physical 2 1 2 1 2 2 2 12 Y N
from garden plucked leaves
to factory
CTC and Metallic Physical 3 3 2 3 3 2 2 18 N Y
Googy shifter contamination
Fermentation Microbial growth Biological 3 3 2 2 2 2 1 15 Y N
Y=Yes; N = No

7
 Ahmad et al.; AFSJ, 13(3): 1-11, 2019; Article no.AFSJ.51947

Table 6. Operational pre-requisite programs (OPRPs) plan for tea industries of Bangladesh

Steps Hazard Monitoring procedure Correction Corrective action

What When How Who
OPRP-1 Physical Condition of the Each -Proper Managerial -Checking -Regular training and proper
Transportation damage of leaves transportation monitoring level staff from - Avoid pressing the direction to the managerial
from garden to the plucked from garden to -Visual garden leaves -Turn over the leaves to avoid
factory leaves factory Supervision operations heat generation or turn the
green leaves into burn.
OPRP-2 Microbial Monitoring Periodic By using Process -Follow proper -Adjust the time
Fermentation growth fermentation time , inspection at thermistor operator or hygienic practices; -Control the temperature below
temperature each operation and supervisor - Maintain optimum 72°F
relative humidity hygrometer condition
and etc.

Table 7. Critical control points (CCPs) plan for tea industries of Bangladesh

Steps Hazard Critical limit Monitoring procedure Correction Corrective action

What When How Who
CCP-1 Plant disease Maximum allowable Health of the -Periodic and - Proper Managerial Adoption of GAP -Allowed pesticides
Cultivation and insect damage by quality plants and timely monitoring level staff and insecticides should
infections control department leaves inspection - Visual from garden be used
or according to supervision operation
regulation
CCP-2 Physical; No metal component Metals Hourly interval -Visual Process - Proper - Check the efficiency
CTC and Metallic detected component or operational inspection operator monitoring of the metal detector
Googy contamination at metal batch wise - By using - Scheduled - Adjust distance
shifter detector interval. correct magnet testing of the all between production
metal detectors line and magnet
- Evaluate the - Informs the quality
record of metal officer
detector inspection - Rejection of the
product

8

Among the 4 significant hazards studied in this
step (Table 5), only the control measures of 2
hazards scored values of over 17. Therefore
these hazards were managed by the HACCP
plan (by establishing CCPs) while rest 2 were
controlled with OPRPs as shown in (Table 6) and
(Table 7) respectively. Earlier based on the
processing technology by analyzing the Hazards
LIN, LI [36] determined 5 CCPs in application of
HACCP on Tartary buckwheat healthful tea in
China.
It was observed that OPRP must be established
for physical hazard in transportation and
biological hazards for Fermentation steps. In the
transportation step, the hazard can be controlled
by adopting Regular training and proper direction
to the managerial and by avoiding pressing and
filing the leaves on the vehicles. In the
fermentation step, the microbial attack can be
controlled by maintaining proper air composition,
optimum fermentation time and temperature.
According to Choudhury [37] it was explored that
the fermentation temperature must be controlled
within 72°F and raise of temperature above this
facilitate the growth of different microorganisms
as well as unwanted secondary reaction which
resulting in quality deterioration of black tea.
The determined 2 CCP were related to both the
cultivation and processing steps. The reason and
significance of determining these two CCP might
be due to the unavailability of prerequisite
programs (PRP) and unconsciousness to the
food safety issue in the tea industries.
At the cultivation step tea plants face different
pests and diseases attack due to the agro-
ecological environment of Bangladesh Good
agricultural practice, good hygiene practice and
proper wastage disposal will be effective to
control them. Therefore the identification of
cultivation step as CCP will ensure the
introduction of HACCP along optimum quality of
tea from the initial stage of tea production.
Another CCP was determined at the very
beginning steps of machinery i.e. CTC and
Googy shifter step to control the physical hazard,
i.e. metal component or other foreign materials.
Therefore this determined CCP will be very
fruitful to maintain the quality of the final tea.
4. CONCLUSION
The HACCP metasystem process is very
important to assure quality which possesses
periodic verification on an ongoing basis by an
9
Ahmad et al.; AFSJ, 13(3): 1-11, 2019; Article no.AFSJ.51947
unbiased third party that certifies the industry.
This study sets out a systematic approach to
adopting HACCP metasystem that is applied
practically to conduct hazard and control
measures assessment. Four significant hazards
have been identified. After assessing the control
measures, CCPs were determined in Cultivation
Step (to control biological hazard) and CTC and
Googy shifter step (to control physical hazard)
while the rest two hazards were managed by
establishing OPRPs. Thus the tea industry by
adopting HACCP metasystem can provide a
guarantee of food safety of tea which may
contribute to increase its acceptability and to
enter new markets. Besides, the developed
HACCP metasystem model of this study can be
conveniently conducted in any tea industry of
Bangladesh to become compliance in quality and
safety.
COMPETING INTERESTS
Authors have declared that no competing
interests exist.
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